operation, service & parts manual - hoist-parts.comhoist/trolley units may be shipped from the...

May, 2003 Copyright 2003, Yale•Lift-Tech, division of Columbus McKinnon Corporation Part No. 117404-10

Printed in U.S.A.

OPERATION, SERVICE & PARTS MANUAL

SERIES Y80

YALE®

WIRE ROPE ELECTRIC HOISTSINCLUDING

WEIGHT WATCHER OVERLOAD CLUTCH MODELS

RATED LOADS 1/2 THRU 5 TONS

Before installing hoist, fill in theinformation below. Refer to theHoist and Motor data plates.

Model No. _________________

Serial No. _________________

Purchase Date _____________

Voltage ___________________

Rated Load _______________

INDEXSECTION I GENERAL DESCRIPTION Page

Paragraph 1-1 General ................................................................................................................................................................. 3Paragraph 1-2 Basic Construction ............................................................................................................................................... 3Paragraph 1-3 Differences Between Models ............................................................................................................................... 3

SECTION II INSTALLATIONParagraph 2-1 General ................................................................................................................................................................. 3Paragraph 2-2 Suspending Hoist ................................................................................................................................................. 3Paragraph 2-3 Connecting Hoist to Electrical Service ................................................................................................................ 4Paragraph 2-4 Pre-Operation Checks .......................................................................................................................................... 4

SECTION III OPERATIONParagraph 3-1 General ................................................................................................................................................................. 6Paragraph 3-2 Push Button Operation ......................................................................................................................................... 6Paragraph 3-3 Overload Clutch Operation (Optional) ................................................................................................................. 6Paragraph 3-4 Operating Precautions .......................................................................................................................................... 6

SECTION IV LUBRICATIONParagraph 4-1 General ................................................................................................................................................................. 7Paragraph 4-2 Change Gear Case Oil ......................................................................................................................................... 7Paragraph 4-3 Lubricate Hoist Cable ........................................................................................................................................... 7Paragraph 4-4 Lubricate Upper Sheave and Lower Block Assembly ......................................................................................... 7Paragraph 4-5 Lubricate Limit Stop Lever .................................................................................................................................... 8Paragraph 4-6 Lubricate Limit Switch .......................................................................................................................................... 8

SECTION V INSPECTION AND PREVENTIVE MAINTENANCEParagraph 5-1 General ................................................................................................................................................................. 8Paragraph 5-2 Inspect Lower Block ............................................................................................................................................. 9Paragraph 5-3 Inspect Upper Block and Hoist Suspension ........................................................................................................ 9Paragraph 5-4 Inspect Electrical Controls .................................................................................................................................... 9Paragraph 5-5 Inspect Motor Brake ........................................................................................................................................... 11Paragraph 5-6 Inspect Mechanical Load Brake, Gearing and Overload Clutch (Optional) ..................................................... 11Paragraph 5-7 Inspect Rope Drum and Shaft ............................................................................................................................ 13Paragraph 5-8 Rope Inspection, Maintenance and Replacement ............................................................................................ 14Paragraph 5-9 Rope Reeving ..................................................................................................................................................... 14Paragraph 5-10 Testing Hoist and Overload Clutch (Optional) ................................................................................................... 17

SECTION Vl TROUBLE SHOOTING CHART ............................................................................................................................ 19-20

SECTION Vll ADJUSTMENTSParagraph 7-1 Mechanical Load Brake ...................................................................................................................................... 21Paragraph 7-2 Motor Brake ......................................................................................................................................................... 21Paragraph 7-3 Block Operated Limit Switch .............................................................................................................................. 21Paragraph 7-4 Screw- Type Limit Switch .................................................................................................................................... 21Paragraph 7-5 Overload Clutch Adjustment .............................................................................................................................. 22

SECTION VIII WIRING DIAGRAMS

SECTION IX PARTS LISTParagraph 9-1 General ............................................................................................................................................................... 22Paragraph 9-2 List of Parts Illustrations ..................................................................................................................................... 22

FOREWORDprovided on the front cover of this Manual for entering this information.We recommend that you fill it out immediately so it is readily at handwhen needed.

The contents of this manual are of necessity, general in nature andmay cover features not incorporated on your hoist; therefore, the usermust exercise care in applying instructions given in this manual. Ifspecific information not in this manual is required, contact the factoryat Muskegon, Michigan 49443.

THE INFORMATION CONTAINED IN THIS MANUAL IS FORINFORMATIONAL PURPOSES ONLY AND YALE•LIFT-TECH DOESNOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OREXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THATYALE•LIFT-TECH MANUFACTURES AND ASSUMES NO LEGALRESPONSIBILITY (INCLUDING, BUT NOT LIMITED TOCONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED INTHIS MANUAL.

No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.

NOTICE: Information contained in this book is subject to change without notice.

This manual contains important information to help you install, operate,maintain and service your new YALE electric hoist. We recommendthat you study its contents thoroughly before putting the hoist into use.Read ANSI B30.16 safety code for hoists. Then, thru proper installation,application of correct operating procedures and by practicing therecommended maintenance suggestions you can expect maximumlifting service from the hoist.

It will likely be a long time before parts information found in Section IXis needed; therefore, after the hoist is installed and you have completelyfamiliarized yourself with operation and preventive maintenanceprocedures, we suggest that this book be carefully filed for futurereference.

When ordering replacement parts from this book, it will be necessarythat you include, with your order, the Hoist Serial Number, ModelNumber and Catalog Number which is found on the nameplate attachedto the hoist electrical cover. For your convenience, a space has been

This brake requires periodic adjustment.

SECTION II — INSTALLATION

2-1. GENERAL. YALE electric hoists are lubricated and testedbefore being shipped from the factory. To place hoist in service,attach to a suitable suspension (paragraph 2-2), connect toelectrical service (paragraph 2-3) and perform pre-operationtests and checks (paragraph 2-4).

2-2. SUSPENDING HOIST. The hoist may be suspended in afixed location servicing only the area directly below the hoist(Lug Mounted) or the hoist may be attached to a moveabletrolley or trolleys which in turn may be mounted on an l-beamattached to a building or crane, servicing a larger area (TrolleyMounted).

a. Lug Mounted hoists attach to adequate supports weldedor bolted to a building or other structure. The supportingstructure must have sufficient strength with appropriate safetyfactor, to support the weight of the hoist and rated load aswell as other loads to which the supporting structure may besubjected.

Steel angles or plates used to suspend hoist should be spacedas close to the hoist suspension lug as possible. Mountingbolts or threaded studs, attaching hoist to mounting structure,shall have a diameter not less than recommended bymanufacturer and material equivalent to ASTM A 325. Makecertain that mounting bolts or studs are long enough so thatthe threads do not engage the mounting support and thatmounting bolts or studs are secured with nuts andlockwashers, self-locking nuts or cross bolting, if unthreaded.

b. Trolley Mounted hoists are attached to moveable trolleys. Ifthe hoist is mounted on an existing trolley, a qualified personshall determine that the trolley and its supporting structureare adequate to support the rated load and weight of thehoist. Hoist/trolley units may be shipped from the factory withtrolley packaged separately. If the trolley can be installeddirectly over the end of the supporting beam, assemble trolleyto hoist. Be certain that the spacing between wheel flanges,after assembly, is 1/4" greater than exact width of beamflange. (See Figure 2-1 below and instruction sheet furnishedwith trolley.) Using proper equipment, carefully lift trolley andhoist and install on end of beam.

SECTION I — GENERAL DESCRIPTION

1-1. GENERAL. YALE electric hoists are precision built wirerope and drum type hoists which are made in five rated loadsizes (1/2, 1, 2, 3 and 5 tons) with various lifts, lifting speedsand electrical service. Equipped with an integrally weldedmounting lug, they are designed to be rigidly attached to anoverhead structure or mounted on YALE rigid mount trolleysfor operation on runway beams. On certain models optionalbase mounting or other supporting methods may be obtained.For full information apply to factory at Muskegon, Michigan49443.

NOTICEYALE hoists are available with an optional built-inmechanical overload clutch. Hoists having this deviceare identified with words WEIGHT WATCHER on thehoist.

The WEIGHT WATCHER overload clutch permits operation ofyour hoist within its rated load and helps prevent lifting ofexcessive loads which could cause permanent deformationof a properly maintained hoist or trolley.

1-2. BASIC CONSTRUCTION. All models are of the samebasic construction and consist of a rugged welded steel framewhich houses a lifting drum and serves as the suspension forcarrying the entire hoist load. A mounting lug, for attachingthe hoist to a trolley or overhead support, is located on top ofthe frame. An aluminum alloy gearcase and cover, attachedto one end of frame, houses a three-reduction gear train anda mechanical load brake. An electric driving motor with disc-type motor brake is located beside the frame, face mountedon the back of the gearcase. Electrical system components,located on the end of the frame (opposite gearcase end) andenclosed by a steel cover, control operation and rotatingdirection of a driving motor. A hoisting rope and an enclosedlower block assembly are used for lifting loads. An upper limitstop is used to limit travel of the lower block in the raisingdirection, to protect hoist from damage. A push button controlstation, for operating the hoist, is suspended from the electricalcompartment.

1-3. DIFFERENCES BETWEEN MODELS. The maindifferences between models are in rope reeving and framesize as described below.

a. Rope Reeving. There are four types of rope reeving used:Two parts of rope single reeved, four parts of rope singlereeved, six parts of rope single reeved and two parts of ropedouble reeved. Single reeved hoists have one end of therope anchored to the drum, whereas, double reeved hoistshave both ends anchored to the drum. On single reevedmodels, the lower block travels sideways as rope winds ondrum, double reeved models offer true ver tical lift. Forillustrations, refer to Section V, paragraph 5-9, “Rope Reeving”instructions.

b. Frame Size. Length of frame furnished is dependent onhoist capacity and lift. Four frame lengths are used; shortframe, long frame, first and second extensions. Short framehoists have a rope drum flange to flange distance ofapproximately 9-3/4", whereas this distance on a long framehoist is approximately 16-3/4". First extension frame hoistshave a flange to flange distance of 22-15/16" and secondextensions have 35-3/8".

c. Motor Brake. Hoists are equipped with a disc brake mountedon the motor end bell and operated by a short stroke solenoid.

Before attempting installation of hoist or trolley, themain power switch must be locked in the open position(off).

WARNING

DO NOT use small holes for attaching this hoist unlessrated load on lower block is 1 (one) ton (2000 Ibs.) orless.

WARNING

Design and installation of hoist support shall beperformed only by qualified persons.

WARNING

For trolleys which are to be mounted along the span of abeam not having open ends, measure exact width of beamflange and assemble trolley to hoist so that spacing betweenwheel flanges is 1/4" (see Figure 2-1) greater than beamwidth (3/8" if beam has curves). This is accomplished byrearranging the spacer washers on the bolts connecting trolleyside plates to hoist mounting lug. If trolley is shipped separatefrom hoist, see instruction sheets furnished with trolley fororientation and installation.

When proper spacing has been determined, loosen mountingnuts (item 1, Figure 2-1) to allow trolley wheels to spread farenough to pass over edges of beam flange. (Some installationsmay require complete removal of one trolley side plate.) Usingadequate equipment, carefully lift the hoist and trolley so thewheel treads will rest on the lower beam flange. Replace sideplate and washers if removed for installation. Replacesuspension stud nuts.

Figure 2-1. Sectional View of Trolley showing proper wheeland washer spacing.

2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.Electrical service to the hoist may be power cable or a guardedsystem having sliding shoe collectors.

Recheck spacer washers to make certain that the numberof washers between the side plate and hoist suspension lugare equal, and also the number on the outside of each sideplate are equal. The suspension stud nuts should only besnugged up on the lockwashers until a load has beenapplied on the hook. A partial load (approx. 25% rated hoistload) placed on the hook will properly seat hoist in thetrolley. Tighten suspension stud nuts only after hoist hasbeen properly seated in the trolley.

CAUTION

a. Follow National, State and Local Electrical Codeswhen providing electrical service to the hoist.

b. Make electrical connections using the appropriate wiringdiagrams furnished with the hoist. All electrical connections,including connections to collectors or power cord, shall bemade only by qualified journeymen electricians.

c. When trolley is shipped separate from hoist, see specialinstructions furnished with trolley for or ientation andinstallation.

2-4. PRE-OPERATION CHECKS.

a. Check Oil Level and Grease Fittings. The gearcase hasbeen filled with oil to the proper level and grease points forlower and upper sheaves have been lubricated at the factory.However, this should be checked before operating hoist. Checkoil level by removing oil level plug with hoist in a level position.Oil level should be at the bottom edge of the plug hole. If not,add oil as specified in Section IV. Grease fittings in lower andupper sheave pins should show evidence of grease.

208/230/460V single speed motors are reconnectable atthe motor. See motor nameplate. Transformer may bereconnected for 200/230/460/575V. See transformer. Checkwith wiring diagram to make certain that motor, transformerand brake leads are properly connected.

CAUTION

Be certain that electrical power supply is off and lockedin the open position before attempting any electricalconnections to the hoist. This equipment must beeffectively grounded according to the National ElectricCode, or other applicable codes. If the groundingmethod used is through the trolley wheels, then eachsection of track must be grounded by metal-to-metalconnection to the building ground. Certainenvironments may prevent proper grounding by thismeans. In this case a separate grounding conductorshould be provided.

WARNING

Mounting of the hoist-trolley unit on the monorail andfinal pre-operation inspection shall be performed onlyby qualified persons properly supervised.

WARNINGThe green wire provided in the power supply cable(when furnished) is a grounding wire and must beconnected to a proper ground.

WARNING

Overfilling of the gearcase may result in the excess fluidbeing expelled through the breather.

CAUTION

11207A

(2) Temporarily connect hoist to power source.

(3) Operate á button briefly to determine direction ofhook travel.

(4) If hook raises, phase is correct. Turn power off andmake temporary connections permanent.

(5) If hook lowers, hoist is “Reverse Phased”. TURNPOWER OFF and correct by interchanging any two leads atpower source connection. Do not change internal wiring ofhoist.

c. Check Limit Switch Operation.

(1) A block operated upper limit stop (Figure 2-2) isfurnished as standard equipment. This limit stop is factoryset to stop lower block in its high position and guard againstover-travel and possible damage to hoist. (Note mountingposition of floating lever for 3 and 5 ton hoists.) No adjustmentcan be made. Limit switch operation should be tested whenhoist is installed. Move hook to a low position by depressingpush button marked â. Now depress button marked �� toraise hook. While hook is traveling upward, manually (or withan extension pole) raise limit stop mechanism (Figure 2-2).

b. Check Push Button Operation and Phasing.

On three phase hoists it is possible to have “ReversePhasing” causing the lower block to lower when the�� button is depressed. When this condition exists,the automatic limit stop switch is inoperative andhoist operation will be dangerous.

WARNING

If any push button binds or sticks in any position —DO NOT TURN POWER ON — determine the causeand correct the malfunction before operating.

WARNING

To properly check the phase of the hoist, follow the stepsbelow:

(1) With “POWER OFF” operate all the push buttonsand determine that they do not bind or stick in any position

When floating rod is raised, stop switch is actuated first andthen the reversing switch is actuated (Figure 2-3). Stop switchstops hoist. Reversing switch lowers hook block in case offloating rod over-travel. If limit switch does not function in thismanner, refer to trouble shooting chart Section Vl for possibleremedy.

Figure 2-2. Limit Stop MechanismBeing Tripped By Lower Block.

Figure 2-3. Electrical Compartment Cover RemovedShowing Limit Switch and Reversing Switch Arrangement.

Do not attempt to make above test with hook in ahigh position near hoist.

WARNING

(2) A screw-type upper and lower limit switch is providedoptionally when both upper and lower limit stops are required(Figure 7-2). This switch is adjustable and must be adjusted,at time hoist is installed, to desired high and low limits oflower block travel. Refer to Section Vll.

d. Check Lower Block and Hoisting Cable. Depress �� pushbutton and run lower block to its lowest position. No less thantwo wraps shall remain on the drum with the loaded hook inits lowest position, unless hoist is equipped with a lower limitswitch in which case no less than one and one half wrapsshall remain on the drum. Also check to see that lower blockand rope does not twist excessively. If it does twist to theextent that two ropes rub against each other, disengage ropefrom the frame anchor and twist rope four or five turns in adirection opposite to that which the block turns. Reconnectrope to anchor (Figure 2-4), holding firmly to eliminate ropetwisting back to its original position. Operate hoist up anddown a few times. If lower block still rotates, repeat processuntil twisting is corrected.

e. Lubricate Hoisting Cable. For longer cable life, it isrecommended that the cable be lubricated at time ofinstallation by applying a Chain and Cable Fluid as outlinedin Section IV, paragraph 4-3.

Figure 2-4. Rope End Anchor.

11403

Safe operation of an overhead hoist is the operator’sresponsibility. Listed below are some basic rules that canmake an operator aware of dangerous practices to avoid andprecautions to take for his own safety and the safety of others.Observance of these rules in addition to frequent examinationsand periodic inspection of the equipment may save injury topersonnel and damage to equipment.

a. DO read ANSI B30.16 Safety Standard for OverheadHoists and the Operation, Service and Parts Manual.

b. DO be familiar with hoist operating controls,procedures and warnings.

c. DO make sure hook travel is in the same direction asshown on controls.

SECTION III — OPERATION

3-1. GENERAL. Operation of Series 800 YALE electric hoistsis controlled by a convenient pendant push button station.With it, the hoist can be controlled to give fast lifting andlowering; or controlled to lift or lower load in small increments,providing accurate spotting. The push button station has abuilt-in interlock to prevent depressing opposing buttonssimultaneously.

When first using hoist, break-in by operating under lighterloads to full travel before applying maximum load.

3-2. PUSH BUTTON OPERATION.

a. Depress push button marked �� to raise load.

b. Depress push button marked �� to lower load.

c. Jogging the push button will give “hairline” load movement.The quickness of the depressing motion will determine theamount of movement. Excessive use of this “Jogging” featurewill cause premature burning of contact tips and motoroverheating.

d. On two-speed hoists, partial depression of button operatesthe hoist at slow speed; depressing button completely operatesthe hoist at fast speed.

3-3. OVERLOAD CLUTCH OPERATION (Optional). Theoverload clutch, when furnished with the hoist, is factorypreset and tested so that the hoist will lift its full rated loadbut will refuse to lift overloads which could cause deformationor weakening of your hoist. If the load to be lifted exceedsthe clutch setting, the hoist motor will continue to run whenthe �� button is depressed and rotate the load brake gearwithout lifting the load. Whenever this slipping occurs,immediately release the �� push button to prevent overheatingof the clutch friction surfaces and the hoist motor.

NOTICEAlways know load to be lifted. Lift-Tech does notrecommend lifting loads greater than the rated load ofyour hoist.

3-4. OPERATING PRECAUTIONS.

Equipment covered herein is not designed or suitableas a power source for lifting or lowering persons.

WARNING

d. DO make sure hoist limit switches function properly.

e. DO maintain firm footing when operating a hoist.

f. DO make sure that load slings or other approvedsingle attachments are properly sized and seated in thehook saddle.

g. DO make sure that the hook latch, is closed and notsupporting any part of the load.

h. DO make sure that load is free to move and will clearall obstructions.

i. DO take up slack carefully, check load balance, lift afew inches and check load holding action beforecontinuing.

j. DO avoid swinging of load or load hook.

k. DO make sure that all persons stay clear of thesuspended load.

l. DO warn personnel of an approaching load.

m. DO protect wire rope from weld splatter or otherdamaging contaminants.

n. DO promptly report any malfunction, unusualperformance, or damage of the hoist.

o. DO inspect hoist regularly, replace damaged or wornparts, and keep appropriate records of maintenance.

p. DO use the hoist manufacturer’s recommended partswhen repairing a hoist.

q. DO use hook latches.

r. DO apply lubricant to wire rope as recommended.

s. DO NOT lift more than rated load.

t. DO NOT use a damaged hoist or a hoist that is notworking correctly.

u. DO NOT use the hoist with twisted, kinked, damagedor worn wire rope.

v. DO NOT lift a load unless wire rope is properly seatedin its drum groove(s).

w. DO NOT use wire rope as a sling or wrap rope aroundthe load.

x. DO NOT lift a load if any binding prevents equalloading on all supporting ropes.

y. DO NOT apply the load to the tip of the hook.

z. DO NOT operate unless load is centered under hoist.

aa. DO NOT allow your attention to be diverted fromoperating the hoist.

ab. DO NOT operate the hoist beyond limits of wire ropetravel.

ac. DO NOT use limit switches as routine operating stopsunless recommended. They are emergency devices only.

ad. DO NOT use hoist to lift, support or transport people.

ae. DO NOT lift loads over people.

af. DO NOT leave a suspended load unattended unlessspecific precautions have been taken.

ag. DO NOT allow sharp contact between two hoists orbetween hoist and obstructions.

ah. DO NOT allow the rope or hook to be used as aground for welding.

ai. DO NOT allow the rope or hook to be touched by alive welding electrode.

aj. DO NOT remove or obscure the warnings on the hoist.

ak. DO NOT adjust or repair a hoist unless qualified toperform hoist maintenance.

al. DO NOT attempt to lengthen the wire rope or repairdamaged wire rope.

am. DO NOT allow personnel not physically fit or properlyqualified to operate hoist.

an. DO NOT operate hoist unless limit switch is operatingproperly.

ao. DO be sure there is no twist in wire rope.

ap. DO avoid operating hoist when hook is not centeredunder hoist. Avoid side pulls and swinging of load orload hook when traveling hoist.

aq. DO operate hoist within recommended duty cycle anddo not “jog’’ unnecessarily.

ar. DO conduct regular visual inspections for signs ofdamage or wear.

as. DO NOT operate hoist with hooks that have openedup. See Figure 5-1.

at. DO provide supporting structure or anchoring meansthat has a load rating at least equal to that of the hoist.

au. DO NOT use hoists in locations that will not allowoperator movement to be free of the load.

av. DO, when starting to lift or pull, move the load a fewinches at which time the hoist should be checked forproper load holding action. The operation shall becontinued only after the operator is assured that the hoistis operating properly.

aw. DO NOT leave a loaded hoist unattended at the endof a work shift or for extended periods during the workshift. Where operations are such that this condition cannotbe avoided the operator must be assured that thecondition does not create a hazard to personnel orproperty.

ax. DO NOT use the hoist load limiting device to measurethe load.

ay. DO NOT operate hoist unless hook moves in the samedirection as indicated on the pushbutton. If oppositedirection occurs, see pre-operation checks, Paragraph 2-4.b.

az. Observe recommended inspection and maintenanceprocedures.

ba. DO use common sense and best judgement wheneveroperating a hoist. Observe American National StandardSafety standard, ANSI B30.16, Iatest issue.

DO NOT operate hoist with the hoisting rope out of thedrum groves. Such operation may result in the ropebreaking and dropping the load which can causedamage to equipment and injury to operator and otherpersonnel. Hoist rope will remain in the drum grovesduring operation under normal operating conditions,however, slack or kinked rope, excessive side pulls,swinging or jerking of load, or similar abuse, may causethe rope to leave the groves.

WARNING

SECTION IV — LUBRICATION

4-1. GENERAL. The lubr icat ion services out l ined inparagraphs 4-2 thru 4-6 should be performed at regularintervals to maintain top hoist performance and ensure longlife. Intervals of at least six (6) months, coinciding with springand fall seasons, are recommended. The reason for this is,on hoists installed out-of-doors and in unheated areas, a“cold test” lubricant is required in cold (below freezing)climates making seasonal changes necessary.

4-2. CHANGE GEARCASE OIL. (Figure 4-1)

a. Remove oil drain plug from bottom of gearcase and drainout oil. (Two drain plugs, one on front and one on back ofgearcase.)

b. Flush out housing using petroleum solvent. Reinstall drainplug.

c. Refill thru oil hole cover to proper level (bottom of oillevel plug hole) using 10 pints of Automatic TransmissionFluid, DEXRON III Type, suitable for all temperature ranges.

Figure 4-1. View Showing Location ofOne Oil Drain Plug.

4-3. LUBRICATE HOISTING CABLE. Hoists are shipped fromthe factory without an exterior coating on hoisting cable. It isrecommended, where conditions permit, that the cable bethoroughly coated at installation and kept well lubricated withLUBRIPLATE Chain and Cable Fluid, or equal, suitable for alltemperature ranges.

4-4. LUBRICATE UPPER SHEAVE AND LOWER BLOCKASSEMBLY.

a. All hoists have grease fittings located in ends of sheavepins. Apply (*) NLGI No. 2 grease for operating temperaturesfrom +50°F to +125°F. For colder temperatures, (-20°F to+50°F) use NLGI No. 1 grease.

b. Apply a few drops of S.A.E. No. 50 oil to hook thrustbearings.

(*) National Lubricating Grease Institute.

4-5. LUBRICATE LIMIT STOP LEVER.

a. Apply a few drops of S.A.E. No. 50 oil to pivot points oflimit rod.

b. Apply a few drops of S.A.E. No. 50 oil to shaft bearing atrear of electrical compartment.

11413A

reports. Inspections are recommended each month and shouldbe performed thoroughly enough to inform the hoist user ofdeficiencies for any item listed. This form does not supersedethe Inspection and Maintenance Schedule listed below butmay be used to record scheduled inspection and maintenanceservices required.

The user should revise the inspection interval, add additionalunits or provide a similar form to suit particular conditionswhich may exist. However, written, dated and signed inspectionreports should be maintained particularly on critical items,such as hoist hooks, hoisting ropes, sheaves, drums andbrakes. Periodic review of old inspection reports can pointout service life of hoist components, forecasting need foradjustment, repair or replacement of these components.

As a matter of expedience, appointed maintenance personnelinspecting the hoist can also take care of minor adjustments,repairs and cleaning, where required. Note the column onInspection Schedule and Maintenance Report form headedCorrective Action and Notes. When corrective action is madeduring inspection, note condition of part or unit as inspectedin appropriate Condition column with a check mark (�). Note“during inspection” corrective action taken and date in spaceprovided. In this manner, items requiring further attention willbe checked (�) without showing corrective action. This willadvise the designated person responsible for hoist operationand safety, who reviews the reports, that deficiencies exist.The designated person will check all deficiencies as listedand reexamine or otherwise determine whether they constitutea safety

Written, dated and signed inspection reports for many itemsare mandatory under OSHA regulations, and many state safetycodes. It is strongly recommended that the InspectionSchedule and Maintenance Report, shown herein, becompleted by a qualified person designated with theresponsibility for hoist operation and safety or an inspectorappointed by this person.

Inspection records can point out the service life of hoistcomponents and help forecast the need for adjustments,repairs and ordering of replacement parts. File and reviewthese reports after each inspection.

4-6. LUBRICATE LIMIT SWITCH. Provide a light film ofNLGI No. 2 grease on bevel gear of limit switch.

SECTION VINSPECTION AND PREVENTIVE

MAINTENANCE

5-1. GENERAL. YALE, Series 800, hoists are inspectedand tested at the factory. Regular in service inspection andpreventive maintenance programs not only help reduce overallmaintenance costs but may also prevent serious shutdownsby forewarning of problems that could cause these shutdowns.Regular inspections, periodic minor adjustments, regularcleaning and lubrication and replacement of worn parts canhelp preserve good performance and operation of your hoist.

Many factors influence the inspection and preventivemaintenance program required for your hoist. Frequency andseverity of service and material handled, local environmentalconditions and various applicable codes are some of thefactors that the user must consider to adjust inspection andmaintenance program outlined in this section to meet hisspecific conditions.

The inspection and maintenance services outlined in thissection are considered minimum. Recommended in theschedule are minimum inspection and maintenance intervalsbased on average daily use in a normal environment. Averagedaily use is based on 1000 operational hours per yearmaximum and intermittent operation of the hoist eight hoursper day, five days per week with a maximum 40% “on” timeand the average loading not exceeding 65% of rated load.

Environmental conditions in which the hoist operates arealso important considerations for the user when adjustinghoist inspection and maintenance programs to local conditions.Frequency of inspection and maintenance must be increasedif hoist is subjected to severe atmospheric environmentalconditions, such as corrosive vapors, extreme heat or cold,cement or dust and other airborne contaminants. The usershould carefully consider all environmental conditions andadjust frequency and degree of maintenance for his localconditions. Consult Lift-Tech Field Service Department foradvice for unusual environmental conditions.

Various codes also regulate inspection and maintenanceprograms. Attention must be given to applicable FederalStandards, OSHA regulations, National Standards, state andlocal codes which may include mandatory rules relating tohoist inspection and maintenance. The user should becomefamiliar with all applicable codes for his area and be guidedaccordingly.

Listed on the Recommended Inspection and MaintenanceSchedule are inspection frequencies and requirements.Perform these inspections regularly as scheduled andadditional inspections as may be required for activity, serviceand environment of your hoist. The hoist operator must beresponsible for determining the operating conditions andseverity of service.

Inspection Schedule and Maintenance Report Form.

Shown on page 10 of this manual is a recommendedInspection Schedule and Maintenance Report form whichlists various components of the hoist. The form also includestrolley components, runway components, and miscellaneousitems. This form is suggested as a guide for written inspection

Deficiencies may be hazardous to personnel andequipment. Do not operate a hoist having deficienciesunless a designated qualified person has determinedthat these deficiencies DO NOT constitute a safetyhazard.

WARNING

Do not operate a hoist having unusual vibrations,sounds or other conditions. Danger may be presentthat the hoist operator cannot see. Determine andcorrect cause of unusual conditions and makecertain the hoist can be operated safely. Be certainto disconnect power to the hoist whenever electricalcover is removed.

WARNING

5-2. INSPECT LOWER BLOCK.

a. Check lubrication of all parts. If the thrust bearing is notequipped with a grease fitting, lubricate with SAE No. 50 oil.Also lubricate the shank of the hook which passes throughthe lower block body.

b. Check each sheave to ensure rope groove is smooth andfree from burrs, or other surface defects.

c. Check each sheave for freedom of rotation; replacebearings if defective.

d. Make certain that dowel pin, holding the hook nut to thehook, is securely in position.

e. If hook is equipped with a safety latch or rotational lock,check to determine that they are in good operating condition.

f. Check throat opening of hook. (Refer to Figure 5-1.) It isrecommended that upon receipt of the hoist a measurementbe made and recorded of the hook throat opening. OSHAStandards require that the hook be replaced if the throatopening exceeds 15 percent of the original opening, or if thehook is twisted more than 10 degrees from the unbent plane.A gage block, properly identified to the hoist, similar to theone shown in Figure 5-1, is suggested to be made for eachhook for use in these measurements.

NOTE: Hooks and hook openings shown are based onhooks normally furnished with standard hoists. Fordimensions of hooks having a special size, shape ormaterial, consult the Muskegon, Michigan factory. Forhooks with certain kinds of safety latches it may benecessary to remove latch to measure hook opening.

g. Hooks showing signs of cracks must be replaced. Hooksshould be inspected at least once per year using dyepenetrants, magnetic particle or other suitable crack detectingmethods.

Figure 5-1. Proper Hook Opening.(Shown with latch removed for clarity.)

h. Check wear of the hook, especially at the saddle andreplace if badly worn.

5-3. INSPECT UPPER BLOCK AND HOIST SUSPENSION.

a. Check upper block sheaves (when hoist is so equipped)for wear, damage and freedom of rotation. If sheaves do notrotate freely, disassemble block and inspect bearings. Replaceworn or damaged bearings, washers, pins or sheaves.

b. Make certain that all sheaves, bearings and hanger pinsare free of foreign material and properly lubricated. Bearingswithout grease fittings are lubricated for the life of the bearingand require no further lubrication. After inspection, lubricateall upper block lubrication fittings.

c. Make certain that rope guide pins are not bent, loose orotherwise distorted; guide pins must have close clearance tosheave flange to keep rope in sheave grooves.

d. Check hoist suspension bolts on lug suspended hoists;make certain that bolts are secure, properly tightened andfree from damage.

e. Inspect suspension lug at top of hoist frame for damage,cracks, hole elongation or other signs of wear. On all hoists,the suspension lug is integral with hoist frame and the entireframe must be replaced when suspension lug is damagedand requires replacement.

f. Reinstall all parts following procedure in reverse ofdisassembly.

5-4. INSPECT ELECTRICAL CONTROLS. Arrangement ofelectrical control equipment varies with the type of control,physical space and the optional control features ordered withthe hoist.

a. Disconnect electrical power to hoist, remove electricalcompartment cover (Figure 9-1, Ref. No. 29) and inspectwiring and terminals. Terminals should be securely crimpedto wires and electrical insulation should be sound. Terminalscrews should be tight.

b. Check condition of contactor assembly, transformer, andlimit stop and reverse switches.

Do not operate a hoist having worn or damagessuspension bolts.

WARNING

HOISTRATEDLOAD

(IN TONS)

HOOKSIZE

(STANDARD)

CORRECT "L"DIMENSION

(NEW HOOK)

1/2 G 1-1/8"1 G 1-1/8"2 H 1-1/4"3 I 1-1/2"5 J 1-3/4"11202A

* See text for DAILY & WEEKLY REQUIREMENTS. SIGNED & DATED REPORT REQUIRED – OSHA.INSPECTION INTERVAL. X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.

INSPECTION SCHEDULE AND MAINTENANCE REPORTHOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________RATED LOAD _________________ LOCATION IN PLANT __________________________________TYPE ________________________ THIS INSPECTION IS MONTHLY � ANNUAL �

VOLTAGE _____________________ SEMI-ANNUAL �

INSPECTED BY: ________________ DATE _____________

*Recom- CONDITIONCOMPONENT, UNIT OR PART mended (Check column best indicating condition when CORRECTIVE ACTION

and location Inspection part or unit is inspected. Use note column to NOTESInterval the right if condition is not listed below.)

COMPONENT,UNIT OR

PART

(Indicate corrective action taken during inspection and note date. For correctiveaction to be done after inspection, a designated person must determine thatthe existing deficiency does not constitute a safety hazard before allowingunit to operate. When corrective action is completed, describe and note datein this column.)

Typical Inspection Schedule and Maintenance Report form.User must adjust inspection interval and components to suit his individual conditions and usage. 12375B

MO

NTH

LY

SE

MI-A

NN

UA

L

AN

NUA

L

GO

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AD

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RE

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RE

QU

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D(L

oose

Par

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ires

)

RE

PLA

CE

ME

NT

RE

QU

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D(W

orn

or D

amag

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LUB

RIC

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NR

EQ

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ED

(Low

Oil

or G

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)

CLE

AN

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OR

PAIN

TIN

GR

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HO

IST

LOC

ATIO

NTR

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RU

NW

AYS

RE

SIS

TOR

SM

ISC

.

DATE

Motor

Motor Brake

Mechanical Load Brake

Overload Clutch

Couplings

Gears, Shafts & Bearings

Upper Block

Lower Block

Hook & Throat Opening X Record Hook Throat Opening

Hoist Rope

Rope Drum

Guards

Limit Switch

Pushbutton

Wiring

Motor

Brake (when so equipped)

Couplings

Gears, Shafts & Bearings

Frame

Wheels

Bumpers

Guards

Conductors

Collectors

Hoist

Trolley

Monorail Joints

Monorail

Main Conductors

Main Collectors

General Condition

Load Attachment Chains

Rope Slings & Connections

Change Gearcase Lub.

Grounding Faults

CO

NTR

OL

STA

TIO

N O

RP

US

H B

UTT

ON

Figure 5-3. View of Gearcase – Cover Removed.

b. To inspect gearing, pull out intermediate gear and pinionassembly and roller thrust bearings (Figure 5-4), and loadbrake assembly (Figure 5-5). Do not remove drum gear unlessvisual inspection indicates replacement is necessary.

c. Inspect gears and pinions for signs of tooth wear anddamage. If replacement of any parts appears necessary,disassemble drum gear, intermediate gear and pinionassembly, and load brake assembly as directed on followingpage.

TIME INTERVAL INSPECTION OR MAINTENANCE

Daily or start Check operation of all functional mechanisms including limit switch operation,of each shift brakes and control. Check hoist cable for kinks, abrasions, corrosion or broken

(\/isual) wires or evidence of improper spooling on drum. Inspect hooks, upper and lowerblocks, and all load bearing components for damage.

1 Month * HOIST CABLE — Inspect and lubricate per paragraph 5-8.

* ELECTRICAL CONTROLS — Inspect per paragraph 5-4.1 - 3 Months

Check hoist gearcase oil level — add oil as required per paragraph 4-2.

6 Months * LOWER BLOCK — Inspect per paragraph 5-2.UPPER BLOCK — Inspect per paragraph 5-3.

Motor brake and actuating mechanisms. Inspect and adjust per paragraph 5-5.Annually * Inspect hooks with suitable crack detecting procedures per paragraph 5-2.

Drain and refill hoist gearcase per paragraph 4-2.

Inspect electrical controls per paragraph 5-4. Change hoist gearcase oil — Fill6 Months or with oil per paragraph 4-2. Lubricate hoist cable per paragraph 4-3. Lubricate500 - 750 hours * upper and lower hook block per paragraph 4-4. Lubricate limit stop lever per“on” time paragraph 4-5. If a screw type limit switch is furnished, add a light film of

NLGI No. 2 grease to bevel gear.

5 Years elapsed Complete inspection, disassembly, and maintenance required. It is recommendedtime or 5000 * that your YALE Repair Station be contacted for this service.hours “on” time

*Perform services described by paragraph indicated.

Figure 5-2. Inspection and Maintenance Schedule.

5-5. INSPECT MOTOR BRAKE. See Figure 9-4.

a. Remove acorn nuts holding brake cover and remove

brake cover.

b. Remove brake mounting plate screws and lift brake

assembly off.

c. Check braking surfaces for wear and scoring. Replacebadly worn or scored parts.

d. Reinstall parts in reverse of disassembly.

e. Adjust brake as explained in Section Vll.

5-6. INSPECT MECHANICAL LOAD BRAKE, GEARING ANDOVERLOAD CLUTCH (Optional).

a. The mechanical load brake and gearing may be inspectedand serviced with hoist suspended. To do so, remove lowerblock and wire rope, drain oil from gearcase, remove 12 hexhead bolts and lockwashers holding gearcase cover, and pullcover from gearcase (Figure 5-3).

11404A

Figure 5-4. Removing Intermediate Gear andPinion Assembly.

Figure 5-5. Removed Load Brake Assembly.

d. To disassemble drum gear, remove external snap ringfrom splined shaft, using heavy-duty snap ring pliers, andpull off gear.

e. To disassemble intermediate gear and pinion, presspinion shaft from gear using an arbor press.

f. It is recommended that load brake assembly be returnedto an Authorized Repair Station for inspection and repair. If itis necessary that you make your own inspection and repair,instructions below must be followed:

(1) Place load brake assembly, flange up, in a viseequipped with brass or copper jaw plates to protect piniongear teeth. Remove snap ring from end of load brake shaft(Figure 5-6).

Figure 5-6. Remove Snap Ring From Load Brake Shaft.

10333

(2) Using a puller tool, remove brake flange from shaft.A groove is provided around outer diameter for this purpose.See Figure 5-7. Remove key from shaft and lift off 2 frictiondiscs, and the pawl and ratchet assembly (Figure 5-8).

Figure 5-7. View Showing Load BrakeFlange Removed.

(3) Remove load brake gear. If replacement of spring,spring retainer or cam is necessary, press off shaft (Figure5-9).

(4) The load brake pawl and ratchet is a rivetedassembly and is not to be disassembled.

(5) Clean all parts thoroughly and inspect for wear anddamage. Replace all parts that are excessively worn ordamaged. Hard surface or glazed friction discs should bereplaced.

Figure 5-8. Removing Pawl and Ratchet AssemblyFrom Load Brake Shaft.

g. Reassemble gearing and load brake parts followingreverse procedure of disassembly. In assembling load brake,observe assembly steps (1) through (4) below:

11422

11421

10334

10335A

(4) The brake spring must be pre-loaded at assembly toa torque of from 10 to 14 lb.-ft. This is accomplished using aplumber’s strap wrench to wind (rotate) load brake gear toset up spring (Figure 5-10) while pressing brake flange intoplace using an arbor press. Clamp pinion end of shaft into aportable vise to keep brake from rotating in press. Use brassor copper jaw plates on vise to protect pinion gear teeth.Wind gear counterclockwise (viewing brake from flange end)with strap wrench and press down on flange until snap ringgroove in shaft is exposed allowing snap ring to be installed.Use extreme care not to over wind spring as yield will resultand final spring torque will be reduced. Do not wind gearbeyond point necessary to install snap ring in groove.

h. Install gearing and load brake assembly in gearcase inreverse order of disassembly. Be certain roller thrust bearingsare installed at both ends of intermediate gear shaft as shownin Figure 5-4 and that thrust washers are properly installed atboth ends of load brake shaft as noted below:

(1) A steel thrust washer with 5/8" I.D. must be installedon the brake flange end (end opposite pinion) of load brakeas shown in Figure 5-5.

(2) A bronze thrust washer with a lug on one side goeson pinion end of load brake shaft and it must be installed sothat its lug engages the special slot located on the spot facesurrounding the load brake bearing bore inside gearcasecover. Use heavy grease to hold it in place on cover as coveris installed.

On hoists with 18 or 20 tooth load brake pinion, an 11/16" I.D. steel thrust washer is installed between pinionand bronze thrust washer.

j. At completion of reassembly of gearing and load brake ingearcase, refill gearcase to proper level using correct gradeof oil, as outlined in Section IV — LUBRICATION.

k. For hoists equipped with an overload clutch (optional)which has been functioning properly, visually inspect clutchadjusting nut and spring washer for signs of damage orlooseness. With a small hex allen wrench, make certain twoset screws in adjusting nut are tight. DO NOT TURNADJUSTING NUT OR DISASSEMBLE CLUTCH. If springwasher, adjusting nut or gear is loose or damaged, or theclutch did not function properly before disassembly of hoistfor inspection, consult the nearest YALE Authorized RepairStation for repair or adjustment.

5-7. INSPECT ROPE DRUM AND SHAFT.

a. To remove drum, remove wire rope, electr icalcompartment cover and electrical panel assembly (Figure9-1) and gearing and load brake assembly (paragraph 5-6).

b. Remove four hex socket head bolts securing gearcase tocover. Three bolts are accessible from inside frame (Figure2-2, Section II) and the fourth is accessible from electricalend of frame thru special access hole using a socket hex keywrench with an extension (Figure 5-11). With bolts removed,pry assembled gearcase and motor from frame. Exercisecaution so that gearcase and motor assembly does not fallas it comes free of frame. This disassembly operation is notrecommended with hoist suspended. Drum will remain in frameand can be lifted from drum shaft. To remove shaft, removeinternal retaining ring from bearing bore in frame.

(1) Before installing spring in its retainer (Figure 5-9), applya good grade of ball bearing grease to inside of retainer.Spring must be positioned exactly as illustrated, butted againstpin at side of cam.

LOAD BRAKE — STANDARD

LOAD BRAKE — OVERLOAD CLUTCH

Figure 5-9. Load Brake Gear Removed FromLoad Brake Showing Load Brake Spring.

(2) When installing pawl and ratchet assembly on loadbrake shaft, be certain that teeth on ratchet face are in thesame direction as shown in Figure 5-8. The ratchet assemblyshould rotate freely when turned counterclockwise and thepawl should engage ratchet teeth when unit is turnedclockwise.

(3) When installing brake flange, position it with chamferfacing friction disc (Figure 5-7).

Figure 5-10. Winding Load Brake Gear Using a StrapWrench to Set Up Load Brake Spring.

Before removing the old rope, refer to reeving diagrams,(Figures 5-12, 5-14, 5-15 and 5-17). Face the rope drum onyour hoist from the side which the rope comes off drum. Toassist with rereeving your hoist, select the reeving diagramfor your hoist. Note the description (such as 2 part doublereeved, Figure 5-17) and refer to the paragraph below withthe same description which describes rereeving procedure.

b. Removing old rope — for all reevings.

(1) Lower the bottom block to a scaffold located 6 to 7feet below hoist to relieve tension on wire rope. (Bottom blockmay be lowered to floor if desired; however, to handle lessweight and for ease of rereeving adequate scaffold below thehoist is recommended.)

(2) Remove bottom block sheave guard.

(3) Remove key plates from both sides of sheave pinand slide sheave pin from bottom block.

(4) Lift out sheaves from the top of the bottom block andremove wire rope.

Figure 5-11. Removing BoltSecuring Gearcase to Frame.

c. Check parts for wear and damage. Replace drum if thereare any signs of cracks or other damage.

5-8. ROPE INSPECTION, MAINTENANCE ANDREPLACEMENT.

a. Inspection. Wire rope on your hoist is one of the mostimportant components requiring frequent inspection andmaintenance. All wire ropes will eventually deteriorate to apoint where they are not safe and will require replacement.

WIRE ROPE SHOULD BE THOROUGHLY INSPECTED ATREGULAR MONTHLY INTERVALS BY AN AUTHORIZEDPERSON AND A DETERMINATION MADE WHEN FURTHERUSE OF THE ROPE WOULD CONSTITUTE A SAFETYHAZARD. Each inspection should include a written, datedand signed report of rope condition. Reports should be filedand reviewed each month and any rope deterioration carefullynoted. Inspections revealing but not limited to the followingconditions should cause the inspector to question remainingstrength of rope and consider replacement:

(1) Twelve randomly distributed broken wires in one ropelay or four broken wires in one strand.

(2) Wear of one-third of the original diameter of outsideindividual wires.

(3) Kinking, crushing or bird caging.

(4) Heat damage from any cause.

(5) Reductions from nominal diameter of more than1/64" for 3/16", 1/4", and 5/16" diameter rope.

(6) Rope corrosion, internal or external.

(7) Effects from improper lubrication.

(8) Rope idle for month or more due to shutdown.

Special attention should be exercised when inspecting ropenormally hidden during inspecting procedures.

Wire rope improperly handled or abused can create aSAFETY HAZARD. Read and comply with inspection,maintenance and replacement information given herein.

WARNING

Use only factory approved rope with swagged wirerope sockets.

WARNING

b. Maintenance. Keep rope well lubricated to help reduceinternal friction and prevent corrosion. Lubricant, as describedin paragraph 4-3, should be applied as a part of the regularmaintenance program. Special attention is required to lubricatesections of rope over equalizing sheaves and other hiddenareas.

Avoid dragging ropes in dirt or around sharp objects whichwill scrape, nick, crush or induce sharp bends in the rope.

c. Replacement. When recommended by an authorizedinspector, the rope should be replaced. Replacement ropeassemblies are shipped from the factory carefully coiled toprevent damage by kinking. Care must be taken to avoidtwisting or kinking when uncoiling and handling during reeving.

Before replacing rope, check condition of grooves in sheavesand drums to determine if they are excessively worn.

When first using the hoist after rope replacement, break-inrope by operating under lighter loads to full travel beforeapplying maximum load.

5-9. ROPE REEVING.

a. General. Before unreeling rope from a coil or reel, besure floor is clean. Dirt picked up by the rope can causeexcessive wear and abrasion. Uncoil the rope by rolling thecoil or reel along the floor; or, place reel on a stand with ashaft thru the center of reel so rope can be pulled straight outwith the reel rotating.

It is imperative that the rope reel or coil rotates as ropeunwinds. If coil or reel does not rotate, the wire will betwisted as it is uncoiled and kinking will result. A kinkedrope may be damaged and unsafe.

CAUTION

With new rope installed on the drum as described in paragraph5-9c single reeved above, proceed with rereeving followingsteps below:

(1) Pass other end of rope thru bottom opening of hoist,between floating limit rod and motor, and attach rope to castdead end anchor fitting. A slot is located at top of fitting toaccept cable. Reinstall bolt and lockwasher in end of anchorfitting to lock rope compression fitting in place.

(2) Grasp loop, formed after installing end anchor, andplace bottom block sheave in loop. Lower sheave into bottomblock and insert sheave pin. Replace key plates and boltsholding sheave pin in place.

(3) Replace sheave guard. Make certain rope is nottwisted. Should the two parts of rope tend to wind aroundeach other, remove cable from anchor slot and untwist cable.Reattach the cable anchor.

(4) Lubricate cable per paragraph 4-3.

(5) Remove key plates or snap rings from upper blocksheave(s) and slide out upper block sheave pins, releasingupper block sheaves. Remove wire rope from sheaves.

(6) Make certain all personnel are clear of hoist andoperate hoist �� to completely unwind all wire rope fromdrum. Stop hoist so drum anchor slot(s) is accessible. Removelive rope and socket(s) from drum.

(7) TURN OFF POWER TO HOIST.

(8) Remove the bolt and lockwasher in the end of therope anchor fitting. Remove rope from slot in top of anchor.

c. Installing new rope.

Winding rope on rope drums with power can behazardous. Keep hands safe distance from drum, weargloves and use extreme care when handling rope.

WARNING

SINGLE REEVED HOISTS

Stretch new cable on floor in one continuous length. Makecertain there is no twist in rope.

(1) Place one end of rope in rope drum anchor slot. Besure end fitting is properly seated.

(2) With all personnel clear of hoist — TURN ONPOWER.

(3) Operate hoist ��, guiding new rope into drum grooveswith gloved hand, until the following lengths remain unwound:

(a) 2 part single reeved — about 14'-0".(b) 4 part single reeved — about 28'-0".(c) 6 part single reeved — about 42'-0".

(4) Proceed with reeving as described in appropriateparagraph below and the reeving diagram for your hoist.

DOUBLE REEVED HOISTS

Stretch new cable on floor in one continuous length. Makecertain there are no twists in rope.

(1) Pull far end of rope toward end of rope nearest hoist,until both ends are even and a loop is formed. Place fittingson both ends of rope in anchor slots on rope drum. Be sureend fittings are properly seated.

(2) With all personnel clear of hoist — TURN ONPOWER.

(3) Operate hoist �� guiding rope into grooves at bothends of drum, until the distance from the drum to the loop is— about 28' for 2 part double reeved.

(4) Proceed with reeving as described in appropriateparagraph below and the reeving diagram for your hoist.

d. Reeving — 2 part single.

See Figure 5-12 for diagram.

See Figure 9-11 for block parts.

Figure 5-12. Hoist Reeving — Two Part Single.

e. Reeving — 4 part single.



With new rope installed on the drum as described inparagraph 5-9c single reeved above, proceed with rereevingfollowing steps below:

(1) Grasp the cable near the middle (about 14'-0") ofthe unwound end and form a loop. Place upper sheave inthis loop. Slide upper sheave with cable into sheave pocket.

(2) Insert sheave pin into sheave. Replace key platesand bolts to hold sheave pin in place.

12203A

Figure 5-13. Upper Sheave Installed.(Typical 3 and 5 Ton)

(3) Pass free end of rope thru bottom opening of hoistbetween floating limit rod and motor, and insert rope in anchorfitting at hoist frame. Be certain power is off before attemptingto place rope in anchor fitting. With end fitting properly seatedin anchor, replace bolt and lockwasher in end of socket. Twoloops have now been formed for bottom block sheaves.

Figure 5-14. Hoist Reeving — Four Part Single.

(4) Place one sheave in each loop. Install one sheavewith cable in bottom block, partially insert sheave pin to holdsheave in place. NOTE: Some blocks have spacer washersbetween sheaves. Be certain that washers are installedbetween sheaves, when shown on parts illustration. Installsecond sheave with cable into bottom block. Slide sheave pinthrough sheave. Replace key plates and bolts securing sheavepin.

(5) Replace sheave guard.


f. Reeving — 6 part single.



With new rope installed on the drum as described in paragraph5-9c single reeved above, proceed with rereeving followingsteps below:

(1) Grasp cable at a point one-third (approx. 14’0") thedistance hanging below the rope drum and form a loop. Placeone upper sheave in this loop. Slide upper sheave with cableinto sheave pocket; partially insert sheave pin to hold sheavein place.

(2) Repeat (1) above and install second upper sheavewith rope. Insert sheave pin and install key plates and boltsto secure sheave pin.

Figure 5-15. Hoist Reeving — Six Part Single.

(3) Pass free end of rope thru bottom opening of hoistbetween floating limit rod and motor and insert in rope anchorfitting at hoist frame. Be certain power is off before attemptingto place rope in anchor fitting. With end fitting properly seatedin anchor, replace bolt and lockwasher in end of socket.Three loops have now been formed for bottom block sheaves.

(4) Place sheave in each loop. Install one sheave withcable in bottom block; partially insert sheave pin to holdsheave in place. NOTE: Be certain that washers are installedbetween sheaves, as shown on parts illustration.

(5) Repeat step 4 for remaining bottom block sheaves.Install sheave pin through sheaves. Replace key plates andbolts securing sheave pin.



g. Reeving — 2 part double.



With new rope installed on the drum as described in paragraph5-9c double reeved above, proceed with rereeving followingsteps below:

(1) Form loops in the two ropes coming from rope drum.Place these loops into bottom block pockets and slide pipe orrod through sheave pin holes. Note position of ropes passinglimit stop bar.

(2) Partially insert upper block sheave pin in openingand install one spacer washer. Raise remaining rope up tohoist, form a loop and place upper sheave in this loop.

12205A

12204A

Figure 5-16. Upper Sheave Installed (Typical).

(3) Place sheave with rope into upper sheave pocketand slide pin partially thru sheave. Install remaining washerand push pin thru side plates. Install snap ring on each endof pin to secure pin in place.

Figure 5-17. Hoist Reeving — Two Part Double.

(4) Insert lower sheave pin into bottom block removingpipe as sheave pin is inserted. Be certain washers arereplaced as shown on parts illustration. With sheave pininstalled, replace key plates and bolts to secure sheave pin.


(6) Lubricate rope per paragraph 4-3.

h. Checking for and removal of rope twisting.

Although rereeving of hoist may have been done carefully,sometimes after new rope has been installed twisting mayoccur. With new rope installed, the hoist block should beraised and lowered several times with gradually increasingloads, through full lift. If the block still rotates excessively atno load, the rope may have twists which should be removed.

(1) To remove rope twist in single reeved hoists.

(a) Observe direction block tends to rotate.

(b) Lower the block to a low position and turn offpower.

(c) Rotate rope near the anchor end several turns ina direction tending to correct block rotation. Thisrotates rope end fitting in the anchor.

(d) Turn on power ; raise and lower the blockseveral times to feed the correcting twist in the ropethrough the reeving.

(e) If block still tends to twist, repeat the aboveprocedure until block rotation is corrected.

(2) To remove rope twist in double reeved hoists.

(a) Observe direction block tends to rotate.

(b) Lower the bottom block unspooling rope from ropedrum until only one quarter (1/4) turn remains torope end anchors in drum.

(c) Rotate rope near ends entering drum in a directiontending to correct block rotation. This rotates ropeend fittings in the drum.

(d) Turn on power; raise and lower the block severaltimes to feed the correcting twist in the rope throughthe reeving.

(e) If block still tends to twist, repeat the aboveprocedure until block rotation is corrected.

5-10. TESTING HOIST AND OVERLOAD CLUTCH(Optional).

a. General. Before placing hoist in service or after disas-sembly and reassembly, hoist should be tested. To test sus-pend hoist from an overhead supporting member of sufficientstrength to support the weight of the hoist and the rated load.Hoists having overload clutches, require an overhead sup-porting structure capable of supporting with appropriate safetyfactor, a load equal to 200 percent rated load and the weightof the hoist. Connect hoist to power supply as shown on hoistnameplate and perform the checks listed in b and c below.

b. Check hoist as outlined in PRE-OPERATION CHECKS,Section II, paragraph 2-4.

c. Check hoist with capacity load.

(1) Attach rated load to lower hook.

(2) Depress �� push button and raise load. When pushbutton is released, hoist should immediately stop and holdload at that level.

(3) Depress �� push button, lower load a short distanceand release button. Hoist should stop immediately and holdload at that level.

NOTE: If load drifts downward slowly in step 2 or3 above, motor brake requires adjustment — seeMOTOR BRAKE ADJUSTMENT — Section Vll —paragraph 7-2.

d. Overload Clutch. The overload clutch (optional) mustbe tested for proper operation before placing hoist in serviceor after disassembly and reassembly of hoist. For testprocedure follow instructions listed below.

12206A

(1) Using a known load, equal to the hoist rated load,energize hoist to lift the load. Raise this load just high enoughto be certain hoist is lifting the entire load. Clutch should notslip with the rated load. Lower load to rest position. If clutchslips with rated load, adjustment is required. (See paragraph7-5. — “OVERLOAD CLUTCH ADJUSTMENT”.) If hoist will liftrated load, proceed to step (2).

(2) Increase load in steps from rated load, TO A MAXIMUMOF 200% of the rated load, attempting to lift load with eachincrease in weight. Hoist Overload Clutch should slip and refuseto lift load before 200% of the rated load is reached. Shouldhoist lift 200% of the rated load — STOP TEST — A CLUTCHADJUSTMENT IS REQUIRED. (See paragraph 7-5 —“OVERLOAD CLUTCH ADJUSTMENT”.)

(3) Run hoist with load causing clutch to slip (hoist refusingload) five cycles of approximately 1 second each.

(4) Remove weights added in step (2) and return to hoist ratedload. Lift rated load one final time. Clutch should not slip.

To prevent overheating, release the hoist control button atonce when the hoist refuses to lift the load.

CAUTION

Do not lift more than rated load except for testpurposes.

WARNING

NOTICE

ALWAYS KNOW LOAD TO BE LIFTED, LIFT-TECHDOES NOT RECOMMEND LIFTING LOADS GREATERTHAN THE RATED LOAD OF YOUR HOIST.

BEFORE ATTEMPTING TO TEST THE OVERLOADCLUTCH, MAKE CERTAIN THE FOLLOWINGPREREQUISITES ARE STRICTLY OBSERVED:

a. An appointed person must determine, beforestarting, that all structures supporting the hoist areadequately strong to withstand the test load of 200%of the rated load, plus the weight of the hoist, whetherhoist is tested in installed position or moved to adesignated test facility.

b. Loads used for testing must be accurately known.

c. Test must be made ONLY by a qualified operator,thoroughly familiar with the hoist and the purpose ofthe test.

d. Adequate and proper rigging must be provided toensure that test loads are securely attached, properlybalanced, and lifted level. Failure to provide adequatesupport could cause injury to personnel and/or damageto equipment.

WARNING

SECTION Vl - TROUBLE SHOOTING

Trouble Probable Cause Remedya. Check switches, circuit breakers or fuses and

connections in power supply lines. Check powercollectors.

b. Check voltage required on motor data plateagainst power supply.

c. Shut off power supply, remove electrical cover onhoist and check wiring connections. Also checkconnections in push button station and limitswitches.

d. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

e. Check transformer fuse. If blown, check forgrounding and/or shorts in the push button station.Check the transformer coi l for signs ofoverheating. Replace transformer if burned out.Verify the transformer secondary is the samevoltage as the coils to which it is connected.

f. Replace motor. Check input power supply. Checkhoist motor connections.

a. Interchange any two power supply line leads.Refer to Section II, paragraph 2-4 b.

b. Check wiring connections with appropriate wiringdiagram.

a. Check for loose connections. See that necessaryjumper wires are properly installed on contactor.

b. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

c. Check push button contacts and wires.

a. Reduce loading to rated load of hoist, as shownon nameplate.

b. Check for loose connections. See that necessaryjumper wires are properly installed on contactor.Check limit switch mounting and connections.

c. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

d. Check push button contacts and wires.

6-1. Hoist Will Not Operate.

6-2. Hook Moves in WrongDirection.

6-3. Hook Will Raise ButNot Lower.

6-4. Hook Will Lower ButNot Raise.

a. No power to hoist.

b. Wrong voltage.

c. Loose or broken wireconnections in hoist electricalsystem.

d. Contactor assembly notfunctioning.

e. No control voltage.

f. Motor burned out.

a. Reverse phasing on three-phase hoists.

b. Hoist wired wrong.

a. Lower electrical circuit open.

b. Contactor assembly notfunctioning.

c. Down, push button inoperative.

a. Excessive load.

b. Hoist electrical circuit open.

c. Contactor assembly notfunctioning.

d. Up, push button inoperative.

SECTION Vl - TROUBLE SHOOTING (Continued)

Trouble Probable Cause Remedy

6-5. Hoist Will Not Lift RatedLoad.

6-6. Hoist Motor Overheats.

6-7. Load Drifts ExcessivelyWhen Hoist Is Stopped.

6-8. Hoist OperatesIntermittently

a. See that power supply current is same voltageIisted on motor data plate. Check hoist motorconnections. Check size of power supply lines.

b. See Section VII, paragraph 7-5.

a. Reduce loading to rated load of hoist, shown onnameplate.

b. Reduce frequency of lifts or amount of jogging.

c. Check current rating on motor data plate againstpower supply. Check hoist motor connections.

d. Disassemble hoist and inspect for defective, wornor damaged parts.

e. See Section VII, paragraph 7-5.

a. Reduce loading to rated load, as shown onnameplate.

b. With No Load, check hoist for drift. If drifting isexcessive, inspect motor brake (Section V,paragraph 5-5) and adjust as outlined in SectionVII, paragraph 7-2.

c. (1) After determining that the motor brake is workingproperly, attach rated load to hook and operatehoist. If the load accelerates during lowering, theload brake is not functioning properly. See SectionV, paragraph 5-6 for replacing worn or damagedparts.

(2) If load brake checks O.K., magnetic motor brakeneeds adjustment (see b. above).

a. Check collectors for free movement of spring arm,weak spring or electrical connections.

b. Check all wiring for loose connections.

a. Low voltage

b. Overload Clutch not properlyadjusted.

a. Excessive load.

b. Excessive duty-cycle.

c. Wrong voltage or frequency.

d. Defective motor or worn bear-ings in hoist frame.

e. Overload Clutch slipping withoutlifting load.

a. Excessive load.

b. Motor brake not holding.

c. Load brake not holding.

a. Collectors make poor contact.

b. Loose connections.

SECTION Vll — ADJUSTMENTS

7-1. MECHANICAL LOAD BRAKE. The mechanical loadbrake on Series 800 YALE hoists is a pawl and ratchet “Weston”type automatic brake. The brake is not adjustable and requiresonly periodic inspection and occasional replacement of thefriction washers.

7-2. MOTOR BRAKE. Instructions for adjusting the brake areinside the brake cover and are repeated below. Check brakeadjustment after the first 30 days of service and regularlythereafter during the six-month inspection procedure. Twoversions of the motor brake occur in this manual.

Figure 7-1A. Motor Brake - Later Version.

Figure 7-1. Motor Brake - Early Version.

a. Examine position of indicating tang located below thesolenoid coil (Figure 7-1 or 7-1A).

b. On the later version of the brake (Figure 7-1A), if the tangis below the line by more than 1/8", the brake should be adjustedto bring the top of the tang back up alongside the line on theadjust label.

c. On the early version of the brake (Figure 7-1), if the tang isbelow the midway position of the two adjustment points shownon the brake, the brake should be adjusted to bring the tangback up alongside the NORMAL position on the brake.

d. Remove the hex key (1/8" size) from the holster on thecover mounting stud and carefully turn the ADJUSTING SCREW(located above the solenoid coil) clockwise. The indicating tangwill move a large distance for a small turn of the adjustingscrew, therefore turn the screw no more than one quarter turnbefore checking adjustment.

e. After adjustment operate the brake by hand to assure brakedisc running clearance. The outboard brake pad should separatefrom the brake disc by approximately .010".

f. Replace hex key in holster.

g Replace brake cover.

7-3. BLOCK OPERATED LIMIT SWITCH. The block operatedupper limit stop, furnished as standard equipment, isnonadjustable and designed to stop lower block at its highpoint of travel to guard against over-travel with possible damageto hoist. When high point is reached, limit stop switchautomatically stops hook travel. If hook drifts upward slightlyafter stop switch is actuated, a reversing switch will close andautomatically reverse direction of hook travel.

7-4. SCREW-TYPE LIMIT SWITCH. This limit switch has arotary screw driven by a gear reduction which is coupled to theend of the drum shaft. Adjustment discs operate the contacts ofseparate switches; one for the hoisting circuit and one for thelowering circuit. The switch assembly must be wired inaccordance with the appropriate wiring diagram, which ispackaged with hoist. Adjustment of this screw-type limit switchis accomplished as follows: (Refer to Figure 7-2).

Before attempting actual adjustments, be certain mainpower switch is OFF and locked in the open position.

WARNING

Figure 7-2. Screw-Type Limit Switch Adjustment.(Wires not Shown for Clarity.)

a. Remove four screws and lift off switch cover.

b. Loosen locking plate screws. Slide locking plate away fromadjustment discs.

12758B

LOCKINGPLATE

SWITCHSWITCH

ADJUSTMENTDISCS

12759

12759C

9-2. INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS

Figure No. Title Page No.9-1 Frame, Gearcase and External Parts ........................................................................................................... 239-2 Gearing and Load Brake Parts ..................................................................................................................... 269-3 Hoist Motor Brake - Later Version ................................................................................................................. 289-4 Hoist Motor Brake - Early Version............................................................................................ .................. 309-5 Three Phase Motor Assembly ....................................................................................................................... 329-6 Upper Limit Switch Parts ............................................................................................................................... 339-7 Electrical Control Equipment ......................................................................................................................... 349-8 Push Button Station Assembly and Conductor Cable (Single Speed) ........................................................ 359-9 Push Button Station Assembly and Conductor Cable (Two Speed) - Later Version ................................... 369-10 Push Button Station Assembly and Conductor Cable (Two Speed) - Early Version ................................... 389-11 Lower Block Assembly — 2 parts rope, single reeved ................................................................................ 409-12 Lower Block Assembly — 2 part double reeved........................................................................................... 419-13 Upper and Lower Block Parts (3 & 5 Ton) .................................................................................................... 429-14 Screw-Type Limit Switch Parts ...................................................................................................................... 43

Provide a light film of NLGI No. 2 grease on bevel gear of limitswitch.

7-5. OVERLOAD CLUTCH ADJUSTMENT. When properlyadjusted, the overload device is designed so that the hoist willlift its full rated load but will refuse to lift an excessive overload.The overload clutch is not externally adjustable. It is necessaryto remove the overload clutch assembly from the hoist for properadjustment. Therefore, it is strongly recommended that whenadjustment and/or replacement parts are required, a SHAWBOXAuthorized Repair Station be contacted. Consult your SHAWBOXDistributor for nearest Repair Station.

SECTION VIII — WIRING DIAGRAMS

Wiring diagrams for SHAWBOX electric hoists have been omittedfrom this book because of many possible variations. This is dueto different currents and types of electrical components used intheir construction. A print of the correct wiring diagram for each

The numbers assigned to the parts of our various assemblies in our parts lists are not the part numbers used inmanufacturing the part. They are identification numbers, that when given with the model number, permit us toidentify, select or manufacture, and ship the correct part needed.

Check limit switch operation carefully, without load,before placing hoist in service. If misadjusted, SEVEREDAMAGE AND/OR A DROPPED LOAD COULD RESULT.Allow 6" for hook drift in both directions. Never allowless than 1-1/2 complete wraps of rope on drum withhook in lowest position.

WARNING

hoist is furnished as a separate insert and shipped with hoist.We suggest you carefully file the wiring diagram with this bookfor future reference.

WHEN ORDERING PARTS OR INFORMATION ON THISEQUIPMENT, ALWAYS INCLUDE MODEL AND SERIALNUMBER ON ORDER.

SECTION IX — PARTS LIST

9-1. GENERAL. The parts lists and illustrations in this sectionof the manual, cover parts for all standard 800 SHAWBOXElectric Hoists. A typical hoist is shown as the basis for theexploded parts illustrations; therefore, certain variations mayoccur from the information given. For this reason, always givethe Hoist Serial Number, Catalog Number, Motor Horsepower,Voltage, Phase, Frequency and Rated Load of Hoist whenordering parts.

Certain parts of your hoist will, in time, require replacementunder normal wear conditions. It is suggested that these partsbe purchased for your hoist as spares for future use. Theseparts are indicated by a (†) symbol at the right side of the partsreference numbers.

c. Turn proper adjustment disc (right for up, left for down)toward stitch to reduce hook travel or away from switch toincrease hook travel.

d. Slide locking plate back into position ensuring slots onadjustment discs are fully engaged, tighten locking plate screwsto 4 in-lbs.

e. Replace cover.

NON-FACTORY AUTHORIZATIONS OR MODIFICATIONOF EQUIPMENT AND USE OF NON-FACTORY REPAIRPARTS CAN LEAD TO DANGEROUS OPERATION ANDINJURY.

TO AVOID INJURY:• Do not alter or modify equipment without factory

authorization.• Do use only factory provided replacement parts.

WARNING

Ref. Part Qty.No. Number Description Req’d

1 800-197 Plug — Oil Level 22 800-192 Cover & Bearing Assembly — Gearcase 13 800-105 Dowel 24† 800-106 Gasket — Gearcase 15 800-107 Gearcase & Bearing Assembly 16 Drum & Hub Assembly (Double Reeved Models) 1

1/2 & 1 Ton (3/6" Dia. Rope)800-109 18' Lift800-111 34' Lift800-2100 47' Lift

2 Ton (1/4" Dia. Rope)800-108 14' Lift800-110 25' Lift800-2101 36' Lift

7 Drum & Hub Assembly (Single Reeved Models) 11/2 & 1 Ton (1/4" Dia. Rope)

800-113 25' Lift800-115 50' Lift

2 Ton (5/16" Dia. Rope)800-112 20' Lift800-114 40' Lift



Figure 9-1. Frame, Gearcase and External Parts.

11455C

Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)

Ref. Part Qty.No. Number Description Req’d.

8 800-116 Screw — Hex, Socket Button Head — Self-Locking 49 Frame Assembly (Single Reeved Models) 1

1/2, 1 & 2 Ton800-117 Short Frame800-118 Long Frame

3 Ton800-2106 First Extension800-2107 Second Extension

5 Ton800-2108 First Extension800-2109 Second Extension

9A Frame Assembly (Double Reeved Models) 11/2, 1 & 2 Ton

800-2110 Short Frame800-2111 Long Frame800-2112 First Extension

12 800-121 Closure — 1/2" Plug 314 800-124 Nut — Hex (Double Reeved Models) 415 800-125 Lockwasher (Double Reeved Models) 419 Shaft — Extension, Drum 1

800-130 Short Frame800-131 Long Frame800-2113 First Extension800-2114 Second Extension

20 800-132 Key — Woodruff (“Hi-Pro” Type) 121 800-133 Ring — Retaining, Hub (Internal) 122† 800-134 Bearing — Drum Shaft 123 800-135 Ring — Retaining, External 124 800-136 Ring — Retaining, Beveled Hub (Internal) 125 800-137a Plate Assembly — Base 126 800-138 Lockwasher 1627 800-139 Screw — Hex Socket Head Cap 429 800-194c Cover Assembly — Electrical 130 800-2121 Screw — Self-Tapping 232 800-146a Plate Assembly — Base (Short Frame) 134 800-2122 Shell — Brake, Short Frame 135 800-149 Screw — Self-Tapping 241 See Fig. 9-3 Motor & Brake 1

& Fig. 9-443 800-155 Screw — Hex Socket Head 144 800-156 Lockwasher 145† Rope & Thimble Assembly (Single Reeved Models) 1

1/2 & 1 Ton (1/4" Dia. Rope)800-158 25' Lift800-161 50' Lift




47 800-164 Screw — Hex Socket Head 448 800-165 Roll Pin 2

NOTES

Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)


49 800-166 Lockwasher 250 800-167 Screw — Hex Head Cap 251 800-168 Key Plate 152 800-169 Shaft — Sheave (Double Reeved Models) 153 800-170 Bracket, Sheave (Double Reeved Models) 154† 800-171 Bearing, Sheave (Double Reeved Models) 155† 800-172 Sheave Assembly, Upper (Double Reeved Models) Includes Bearing 156† Rope & Thimble Assembly (Double Reeved Models) 1

1/2 & 1 Ton (3/16" Dia. Rope)800-174 18' Lift800-176 34' Lift800-2119 47' Lift

2 Ton (1/4" Dia. Rope)800-173 14' Lift800-175 25' Lift800-2120 36' Lift

57 800-177 Plug, Pin 258 800-178 Bolt, Hex Head 1261 800-196 Label, Rated Load (Specify Rated Load) 1

†Recommended spares.

Figure 9-2. Gearing and Load Brake Parts.

Ref. Part Qty.No. Number Description Req’d.1† 800-201 Bearing Assembly — Needle, Intermediate & Drum Gear Shaft 22† 800-202 Race — Thrust Bearing 43† 800-203 Bearing Assembly — Needle Thrust 24 Gear — Intermediate 1

800-204 104 Teeth800-205 109 Teeth800-266 103 Teeth800-206 90 Teeth800-2205A 107 Teeth

5 800-207 Key — Woodruff 17 Gear — Drum 1

800-209 71 Teeth800-210 61 Teeth800-2209 71 Teeth

8 Shaft — Intermediate Gear 1800-211 14 Teeth800-212 24 Teeth800-2211 14 Teeth

11456LC

Figure 9-2. Gearing and Load Brake Parts. (Cont’d.)


15 800-219 Ring — Retaining, Drum Shaft Bearing 117 800-221 Ring — Retaining 118† 800-222 Bearing Assembly — Roller, Intermediate Shaft 119 800-269 Cover — Oil Hole 120 800-224 Pipe Plug — Hex Socket 121† 800-225 Oil Seal — Motor Shaft 122† 800-226 Bearing Assembly — Ball, Motor Shaft 123† 800-227 Bearing Assembly — Needle, Load Brake Shaft 124 800-228 Ring — Retaining, Motor Shaft Bearing 125 800-229 Washer — Thrust (Steel) 1

Brake Assembly — Load, Complete (Includes Items 26 thru 37) 1800-230 23 Teeth800-231 36 Teeth800-267 24 Teeth800-232 18 Teeth

800-2232A 20 Teeth26 800-233 Ring — Retaining, Brake Flange 127 800-234 Flange — Load Brake 128* 800-235 Washer — Friction 229 800-236 Pawl & Ratchet Assembly — Load Brake (Available Only As An Assembly) 130 800-237 Bushing — Ratchet 131 800-238 Gear & Center Assembly 132 800-239 Pin — Groove 233† 800-240 Cam — Load Brake 134† 800-241 Spring — Load Brake 135 800-242 Retainer — Spring, Load Brake 136 800-243 Key — Woodruff 237 Shaft & Integral Pinion — Load Brake 1

800-244 23 Teeth800-245 36 Teeth800-268 24 Teeth800-246 18 Teeth

800-2246A 20 Teeth38† 800-247 Washer — Thrust (Used With 800-246 Only) 139† 800-248 Washer — Thrust (Bronze) 140† 800-249 Bearing Assembly — Needle, Load Brake Shaft 1

* 800-250 Load Brake — Clutch Assembly With Bearings (Complete) 1** 800-251 Load Brake — Clutch Assembly (Includes Items 26 thru 30, 34, 36 thru 38

and 43 thru 45) 143 800-254 Spring Retainer

Available only as part of44 800-253 Brake Gear, Center } 800-250 or 800-251 above45 800-252 Clutch Assembly46 800-260 Ring — Retaining 347 800-263 Oil Seal — Drum Shaft 148 800-261 Bearing Assembly — Ball, Drum Shaft 149 800-262 Shaft — Drum 1

† Recommended spares.* Recommended Replacement Kit for Load Brake Clutch (Complete).** Replacement Complete, Less Bearings and Thrust Washers.For hoists built prior to March, 1997, gearing part numbers, with four digits (rather than three) after “800-”, must be replaced in sets.For hoists built between March 1, 1997 and July 1, 1997, contact the factory for gearing requirements.

Figure 9-3. Hoist Motor Brake - Later Version.


800-2401 Motor Brake Assembly (Includes Ref. Nos. 1 thru 31) 11 * Acorn Nut - Plated (#10-32) 22 800-2402 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 13 * Cover Stud 24 * Gasket 15 * Phillips Pan Head Self Tapping Screw - Plated (#10-32 x 1-3/4) 46 * Solenoid Frame Cover Assembly 17 * Hex Key (1/8 - 3/4 x 2) 18 800-2410† Solenoid Coil Assembly 19 * Tubing 3

10 * Hex Nut - Plated (#10-32) 211 800-2411 Solenoid Frame 114 * Hex Head Self Locking Nut - Plated (#10-32) 215 800-2403 Solenoid Support 116 * Hex Washer Head Thread Forming Screw - Plated (#10-32 x 1/4) 217 * Solenoid Plunger 118 * Hex Socket Head Set Screw - Oval Point (1/4-28 x 1) 119 * Hex Socket Shoulder Screw (#10-24 x 1)** 120 * Hex Head Self Locking Nut - Plated (#10-24)** 121 * Brake Spring (Use Red Spring Only) 122 * Brake Lever Assembly 123 * Pressure Pad 224 Brake Disc (Non-asbestos) 125 * Brake Support Stud 226 * Separating Spring 227 800-2404 Brake Mounting Plate 128 * Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8) 229 * Brake Hub 130 * Hex Socket Head Screw (3/8-16 x 3/4) 231 Lock Washer (3/8) 2

Wire Nuts — Not Shown (No. 22 thru 14 AWG) 4* Not available as individual parts. See replacement kits listed below.** Later models have a hex socket head screw (1/4-20 x 1-1/2) with a hex head self locking nut - plated (1/4-20).Kits include quantities shown above.

12756H

NOTES

Figure 9-3. Hoist Motor Brake. (Cont’d.)

Kit Description Part Number Reference Numbers Included

Brake Disc 800-2405† 23, 24, 26

Brake Lever 800-2406 6, 15, 17, 18, 19, 20, 21 (Red Color), 22,Adjusting Screw Label, Brake Adjust Label —Discard Zinc Colored Spring

Rectifier 800-2407 12, 13, 4 Wire Nuts

Hardware 800-2408 1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31,Instruction Label, Power Warning Label

Brake Hub 800-2409 28, 29, Hub Drive Key (Shown Elsewhere)

† Recommended spares.

Figure 9-4. Hoist Motor Brake - Early Version.


Motor Brake Assembly (Includes Ref. Nos. 1 thru 32) 1800-1400 Short Frame Models Only800-1401 Other Models

1 * Acorn Nut (#10-32) 22 800-1402 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 13 * Cover Stud 24 * Gasket 15 * Hex Washer Head Thread Forming Screw (#10-32 x 1 -3/4) 46 * Solenoid Frame Cover Assembly 17 * Hex Key (1/8-3/4 x 2-1/4) 18 * Solenoid Coil Assembly 19 * Tubing 3

10 * Hex Nut (#10-32 Pltd.) 211 * Solenoid Frame 114 * Hex Head Self-Locking Nut (#10-24) 215 800-1403 Solenoid Support 116 * Hex Washer Head Thread Forming Screw (#10-32 x 1/4) 217 * Solenoid Plunger 118 800-1404 Hex Socket Head Self-Locking Set Screw - Oval Point (1/4 - 28 x 1) 120 * Clevis Pin (3/16 x 1-1/4) 121 * Flat Washer 222 * Brake Spring 123 * Brake Lever Assembly 124 * Pressure Pad 225 * Brake Disc (Non-asbestos) 126 * Brake Support Stud 227 * Separating Spring 228 * Hex Socket Head Self-Locking Set Screw - Cup Point (1/4 - 20 x 3/8) 229 * Brake Hub 130 * Hex Socket Head Screw (3/8 - 16 x 3/4) 231 800-1405 Brake Mounting Plate 132 * Wire Nuts — Not Shown (No. 22 thru 16 AWG) 4

* Not available as individual parts. See replacement kits listed below. Kits include quantities shown above.

12756A

NOTES

Figure 9-4. Hoist Motor Brake. (Cont’d.)

Kit Description Part Number Reference Numbers IncludedBrake Disc 800-1406 24, 25, 27

Solenoid 800-1407 5, 6, 8, 11, 17

Brake Lever 800-1408 18, 20, 21, 22, 23

Brake Hub 800-1409 28, 29, Hub Drive Key (Shown Elsewhere)

Special Hardware 800-1410 3, 4, 9, 26, Instruction Label inside cover,Adjust Label, Adjusting Screw Label onbrake lever assembly, Power Warning Labelon cover

Hardware 800-1411 1, 5, 7, 10, 12, 14, 16, 18, 20, 21, 28, 30

Figure 9-5. Three Phase Motor Assembly.


Motor Assembly (Includes Ref. Nos. 1 thru 8) 11 Horsepower (1 Speed)

800-1301 200 Volt800-1302 230/460 Volt800-1303 575 Volt

2 Horsepower (1 Speed)800-1304 200 Volt800-1305 230/460 Volt800-1306 575 Volt

4 Horsepower (1 Speed)800-1307 200 Volt800-1308 230/460 Volt800-1309 575 Volt

1 - 1/3 Horsepower (2 Speed)800-1310 200 Volt800-1311 230 Volt800-1312 460 Volt800-1313 575 Volt

2 - 2/3 Horsepower (2 Speed)800-1314 200 Volt800-1315 230 Volt800-1316 460 Volt800-1317 575 Volt

3 - 1 Horsepower (2 Speed)800-1318 200 Volt800-1319 230 Volt800-1320 460 Volt800-1321 575 Volt

4 - 2 Horsepower (2 Speed)800-1322 200 Volt800-1323 230 Volt800-1324 460 Volt800-1325 575 Volt

1 * Bell — End 12 * Ring — Retaining 13 * Bearing — Ball 14 * Ring — Retaining 15 * Key — Brake 16 * Rotor and Shaft Assembly 17 * Stator Assembly 18 * Bolt — Motor 4

* Furnished only as part of motor assembly.

12724

Figure 9-6. Upper Limit Switch Parts.


1 800-501 Pin — Pivot 22 Arm — Lever 1

800-502 Short Frame800-503 Long Frame800-526 First Extension800-527 Second Extension

3 Lever — Floating 1800-504 Short Frame800-505 Long Frame800-528 First Extension800-529 Second Extension

4 800-506 Washer 25 800-507 Pin — Cotter 26 800-525 Coupling 17 800-509 Pin — Roll 28† 800-510 Switch Assembly — Limit, Reversing (Includes Wire Leads) 19 800-511 Connector — Wire 3

10† 800-512 Switch Assembly — Limit, Stop (Includes Wire Leads) 111 800-513 Screw — Round Head 412 800-514 Screw — Socket Head Shoulder 113 800-515 Shaft & Cam Assembly 114 800-516 Insulator — Limit Switch 115 800-517 Bearing — Nylon 216 800-518 Screw — Socket Head Cap 217 800-519 Lockwasher 218 800-520 Nut — Lock 119 800-521 Bracket Assembly — Mounting 120 800-522 Nut — Hex 2

† Recommended Spares.

11460

Figure 9-7. Electrical Control Equipment.


3 800-670 Cord Grip — Conductor 25 800-654 Screw — Self-Tapping 46† 800-655 Contactor — Two Speed 17† 800-656 Contactor 18 800-657 Screw — Self-Tapping 29† 800-671 Transformer 1

10 800-663 Screw — Self-Tapping 411† 800-672 Terminal Board (Reconnectable Hoist Only) 112 800-673 Fuse, Fuse Holder and Wire Assembly 1

800-674 Fuse Only (2A, 300V) 113 800-675 Brake Module 114 800-676 Screw — Self Tapping 2


NOTES

12748A

Figure 9-8. Push Button Station and Conductor Cable Assembly.Single Speed Hoists.


800-2701 Push Button Station and Conductor Cable Assembly(Includes Ref. Nos. 1 thru 17) 1

800-2702 Push Button Station (Includes Ref. Nos. 1 thru 15) 11 * Type 1 Pan Head Machine Screw (M 3.5 x 0.6 x 12 Pltd.) 72 * Lockwasher (M 3.5 Pltd.) 73 * Rear Cover 14 800-2703 Gasket 15 * Type 1 Pan Head Thread Cutting Screw (M 4 x 15 Pltd.) 26 800-2704 Contact Assembly 17 800-2705 Button Assembly 18 * Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.) 19 * Lockwasher (M 6 Pltd.) 110 * Plain Washer (M 6 Pltd.) 111 * Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.) 212 * Lockwasher (M 3.5 Pltd.) 213 * Housing Cap 114 800-2706 Grommet 115 * Housing 116 800-2707 Conductor Cable Assembly 117 800-2708 Plastic Warning Tag 1

* Not available separately. Order Push Button Station.

12763



1 800-1822 Grommet 17 800-1823 Conductor Cable As Req’d11 800-1812 Operator Warning Label 1

800-1813 Push Button Station (Includes Ref. Nos. 12 thru 30) 112 800-1814 Sleeve — Conductor 113 * Support — Strain Cable 114 * Screw — Slotted Head 415 * Lockwasher 416 * Enclosure — Rear 117 * Gasket 118 * Screw — Slotted Head 219 * Screw — Slotted Head 2

12721A

Figure 9-9. Push Button Station and Conductor Cable Assembly.Two Speed Hoists Only - Later Version.

Figure 9-9. Push Button Station and Conductor Cable Assembly. (Cont’d.)


20 * Clamp — Conductor 121 * Contact Block Assembly 1

800-1815 Contact Block (ZB2-BE101) 2800-1816 Contact Block (ZB2-BE201) 2

22 * Interlock—Mechanical 1800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and

25 thru 29) 1800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,

25 thru 28 and 30) 123 ** Ring — Retaining 224 * Enclosure — Front 125 ** Seat — Spring 226 ** Spring 227 ** Seal 228 ** Plate — Push Button 229 ** Push Button — Up 130 ** Push Button — Down 1

* Not available separately. Order Push Button Station.** Not available separately. Order Push Button Assembly.

NOTES

Figure 9-10. Push Button Station and Conductor Cable Assembly.Two Speed Hoists Only - Early Version.



1 800-1802 Anchor Bracket — Strain Cable 12 800-1803 Grip Assembly — Conductor 13 800-1804 Connector — Strain Cable 14 800-1805 Thimble — Strain Cable 25 800 1806 Connector — Conductor to Strain Cable 16 800-1807 Clamp — Conductor 17 800-1808 Conductor Cable 18 800-1809 Strain Cable 19 800-1810 Sleeve — Pressure 110 800-1811 Tie — Conductor As Req’d.11 800-1812 Operator Warning Label 1

800-1813 Push Button Station (Includes Ref. Nos. 12 thru 30) 112 800-1814 Sleeve — Conductor 1

12721

Figure 9-10. Push Button Station and Conductor Cable Assembly. (Cont’d.)


13 * Support — Strain Cable 114 * Screw — Slotted Head 415 * Lockwasher 416 * Enclosure — Rear 117 * Gasket 118 * Screw — Slotted Head 219 * Screw — Slotted Head 220 * Clamp — Conductor 121 * Contact Block Assembly 1

800-1815 Contact Block (ZB2-BE101) 2800-1816 Contact Block (ZB2-BE201) 2

22 * Interlock — Mechanical 1800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and

25 thru 29) 1800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,

25 thru 28 and 30) 123 ** Ring — Retaining 224 * Enclosure — Front 125 ** Seat — Spring 226 ** Spring 227 ** Seal 228 ** Plate — Push Button 229 ** Push Button — Up 130 ** Push Button — Down 1

* Not available separately. Order Push Button Station.** Not available separately. Order Push Button Assembly.

NOTES

Figure 9-11. Lower Block Assembly — Two Parts Rope, Single Reeved.


800-801 Block Assembly — Lower, Complete, 2 Ton 1800-802 Block Assembly — Lower, Complete, 1 Ton 1800-803 Block Assembly — Lower, Complete, 1/2 Ton 1

1 800-804 Screw — Flat Head, Self-Threading 22 800-805 Cover — 2 Ton 1

800-806 Cover — 1 Ton 1800-807 Cover — 1/2 Ton 1

3 800-808 Ring — Retaining, 2 Ton 2800-809 Ring — Retaining, 1/2 & 1 Ton 2

4 800-810 Lube Fitting 15 800-811 Pin — Sheave, 2 Ton 1

800-812 Pin — Sheave, 1/2 & 1 Ton 16 800-813 Spacers — 2 Ton 2

800-814 Spacers — 1/2 Ton & 1 Ton 2† 800-815 Sheave Assembly — 2 Ton (Consists of Items 7 and 8) 1

7 800-816 Bearing 18 800-817 Sheave 1

† 800-818 Sheave Assembly — 1/2 & 1 Ton (Consists of Items 7 and 8) 17 800-819 Bearing 18 800-820 Sheave 19 800-821 Cover — Lower Block, 2 Ton 1

800-822 Cover — Lower Block, 1 Ton 1800-823 Cover — Lower Block, 1/2 Ton 1

10† 800-824 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton 1† 800-825 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton 1

11 800-826 Shroud — Thrust Bearing, 2 Ton 1800-827 Shroud — Thrust Bearing, 1/2 & 1 Ton 1

12† 800-828 Bearing Washer -— Thrust, 2 Ton 1† 800-829 Bearing Washer — Thrust, 1/2 & 1 Ton 1

13 800-830 Body — Lower Block, 2 Ton 1800-831 Body — Lower Block, 1/2 & 1 Ton 1

14 800-832 *Safety Hook Latch Kit — 2 Ton 1800-833 *Safety Hook Latch Kit — 1/2 & 1 Ton 1

15 800-834 Screw — Flat Head, Self-Threading 2


11464

Figure 9-12. Lower Block Assembly—Two Parts Double Reeved.


800-851 Block Assembly — Lower, Complete, 2 Ton 1800-852 Block Assembly — Lower, Complete, 1 Ton 1800-853 Block Assembly — Lower, Complete, 1/2 Ton 1

1 800-804 Screw — Flat Heads Self-Threading 42 800-854 Cover — Lower Block, 2 Ton 2

800-806 Cover — Lower Block, 1 Ton 2800-807 Cover — Lower Block, 1/2 Ton 2

3 800-809 Ring — Retaining 24 800-810 Fitting — Lube 15 800-855 Pin — Sheave 16 800-814 Spacer 4

† 800-818 Sheave Assembly — (Consists of Items 7 and 8) 27 800-819 Bearing 28 800-820 Sheave 29 800-856 Cover — Intermediate 1

10 800-834 Screw — Flat Head, Self-Threading 411 † 800-824 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton 1

† 800-825 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton 112 800-826 Shroud — Thrust Bearing, 2 Ton 1

800-827 Shroud — Thrust Bearing, 1/2 & 1 Ton 113 † 800-828 Bearing — Thrust, 2 Ton 1

† 800-829 Bearing — Thrust, 1/2 & 1 Ton 114 800-857 Body — Lower Block, 2 Ton 1

800-858 Body — Lower Block, 1/2 & 1 Ton 115 800-832 *Safety Hook Latch Assembly — 2 Ton 1

800-833 *Safety Hook Latch Assembly — 1/2 & 1 Ton 1

† Recommended Spares.* Furnished as Standard with hook.

11465

Quantity Required

Ref. Part ReevingNo. Number Description 3-Ton/4 PS 5-Ton/6 PS

800-1501 Block Assembly — Lower, 4 Part Single (Complete) 1 —800-1502 Block Assembly — Lower, 6 Part Single (Complete) — 1

1 800-1503 Screw — Hex Head Cap 2 22 800-1504 Lockwasher 2 23 800-1505 Key Plate 1 14 800-1506 Fitting — Grease 1 15 800-1507 Pin — Upper Sheave 1 16 800-1508 Spacer Washer — Upper Sheave 2 47† 800-1509 Bearing — Upper Sheave (Includes Outer Race) 1 28† 800-1510 Sheave — Upper 1 29 800-1535 Pin — Rope Guide 2 211 800-1513 Spacer Washer — Lower Sheave 4 6

12† 800-1514 Bearing — Lower Sheave (Includes Outer Race) 2 313† 800-1515 Sheave — Lower 2 314 800-1516 Pin — Roll, Hook Nut 1 115 800-1517 Nut — Hook* 1 1

16† 800-1518 Bearing — Thrust, Hook 1 1800-1530 Shield — Bearing (Not Shown) 1 —800-1531 Washer — Thrust (Not Shown) 2 —

17 800-1519 Fitting — Grease 1 118† 800-1520 Hook Assembly — (includes Hook, Latch & Nut) 1 119 800-1521 Plate — Capacity 2 220 800-1522 Screw — Round Head, Self-Tapping (Capacity Plate) 4 421 800-1523 Guard — Sheave 1 122 800-1524 Body — Lower Block 1 123 800-1525 Pin — Lower Sheave 1 124 800-1526 Screw — Button Head Cap, Self-Locking (Sheave Guard) 4 425 800-1527 Ring — Retaining, External 2 226 800-1528 Lockwasher — (Capacity Plate) 4 427 800-1529 Spacer — Upper Block, 9/16" 2 —

† Recommended Spares.* Hook Nuts with roll pins are not interchangeable — Available only as an assembly.

Figure 9-13. Upper and Lower Block Parts (3 & 5 Ton — Typical).

12197LA

Figure 9-14. Screw-Type Limit Switch Parts.


1 800-1655 Limit Switch Assembly (Includes Ref. Nos. 2, 3 and 4) 12 800-1651 Cap Screw — Hex Socket Head 33 800-1652 Sealing Washer 34 800-1657 Drum Shaft Insert 1

For switch element replacement order 800-1654.

NOTES

12757A

A. Seller warrants that its products and parts, when shipped, and itswork (including installation, construction and start-up), when performed,will meet applicable specifications, will be of good quality and will befree from defects in material and workmanship. All claims for defectiveproducts or parts under this warranty must be made in writingimmediately upon discovery and in any event, within one (1) year fromshipment of the applicable item unless Seller specifically assumesinstallation, construction or start-up responsibility. All claims fordefective products or parts when Seller specifically assumesinstallation, construction or start-up responsibility and all claims fordefective work must be made in writing immediately upon discoveryand in any event, within one (1) year from completion of the applicablework by Seller, provided; however, all claims for defective productsand parts made in writing no later than eighteen (18) months aftershipment. Defective items must be held for Seller’s inspection andreturned to the original f.o.b. point upon request. THE ‘FOREGOINGIS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIESWHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS.

WARRANTYWARRANTY AND LIMITATION OF REMEDY AND LIABILITY

B. Upon Buyer’s submission of a claim as provided above and itssubstantiation, Seller shall at its option either (i) repair or replace itsproduct, part or work at either the original f.o.b. point of delivery or atSeller’s authorized service station nearest Buyer or (ii) refund anequitable portion of the purchase price.

C. This warranty is contingent upon Buyer’s proper maintenance andcare of Seller’s products, and does not extend to normal wear andtear. Seller reserves the right to void warranty in event of Buyer’s useof inappropriate materials in the course of repair or maintenance, orif Seller’s products have been dismantled prior to submission to Sellerfor warranty inspection.

D. The foregoing is Seller’s only obligation and Buyer’s exclusiveremedy for breach of warranty and is Buyer’s exclusive remedyhereunder by way of breach of contract, tort, strict liability or otherwise.In no event shall Buyer be entitled to or Seller liable for incidental orconsequential damages. Any action for breach of this agreementmust be commenced within one (1) year after the cause of action hasaccrued.

Recommended Spare Parts for Your Yale Hoist

Certain parts of your hoist will, in time, require replacement under normal wear conditions.It is suggested that the following parts be purchased for your hoist as spares for future use.

One Friction Disc Kit

One Motor Brake Solenoid Coil

One Set Of Contactors

One Transformer

One Wire Rope Assembly

One Gearcase Gasket

Note: When ordering parts always furnish Hoist Serial Number, Catalog Number, Motor Horsepower, Voltage,Phase, Frequency and Rated Load of Hoist on which the parts are to be used.

Parts for your hoist are available from your local authorized SHAW-BOX repair station.For the location of your nearest repair station, write:

IN USA

Yale��Lift-TechP.O. Box 769Muskegon, MI 49443-0769

Phone: 800 742-9269Fax: 800 742-9270

operation, service & parts manual - hoist-parts.comhoist/trolley units may be shipped from the...

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